U.S. patent application number 17/310697 was filed with the patent office on 2022-04-21 for aerosol provision systems.
The applicant listed for this patent is Nicoventures Trading Limited. Invention is credited to Steve HUGHES, David Alan NELSON.
Application Number | 20220117310 17/310697 |
Document ID | / |
Family ID | |
Filed Date | 2022-04-21 |
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United States Patent
Application |
20220117310 |
Kind Code |
A1 |
NELSON; David Alan ; et
al. |
April 21, 2022 |
AEROSOL PROVISION SYSTEMS
Abstract
A cartridge for an aerosol provision system comprising the
cartridge and a control unit. The cartridge comprises: an air
channel extending from an air inlet for the cartridge to an outlet
via an aerosol generation region; a heating element for heating
aerosolizable material, such as liquid, from a reservoir to
generate aerosol in the aerosol generation region; and a valve
located in the air channel upstream of the aerosol generating
region. The cartridge is configured such that air passing through
the air channel is configured to pass from the air inlet, past the
air valve, into the aerosol generating region, and then out from
the aerosol outlet.
Inventors: |
NELSON; David Alan;
(Hampshire, GB) ; HUGHES; Steve; (London,
GB) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Nicoventures Trading Limited |
London |
|
GB |
|
|
Appl. No.: |
17/310697 |
Filed: |
February 18, 2020 |
PCT Filed: |
February 18, 2020 |
PCT NO: |
PCT/GB2020/050376 |
371 Date: |
August 18, 2021 |
International
Class: |
A24F 40/485 20060101
A24F040/485; A24F 40/44 20060101 A24F040/44; A24F 40/42 20060101
A24F040/42; A24F 40/70 20060101 A24F040/70 |
Foreign Application Data
Date |
Code |
Application Number |
Feb 18, 2019 |
GB |
1902220.1 |
Claims
1-74. (canceled)
75. A cartridge for an aerosol provision system comprising the
cartridge and a control unit, wherein the cartridge comprises: a
housing part having a mouthpiece end and an interface end, wherein
the mouthpiece end includes an aerosol outlet for the cartridge and
the interface end includes an interface for coupling the cartridge
to a control unit; an air channel extending from an air inlet in
the housing part to the aerosol outlet; a reservoir within the
housing part containing liquid for aerosolizing, wherein the
reservoir includes a dividing wall element defining a dividing wall
between a first reservoir region on a side of the dividing wall
facing the mouth piece end of the housing part and a second
reservoir region on a side of the dividing wall facing the
interface end of the housing part, wherein the dividing wall
comprises at least one fluid communication opening to provide fluid
communication between the first reservoir region and the second
reservoir region; a liquid transport element arranged to transport
liquid from the second region of the reservoir to a heating element
for generating aerosol in an aerosol generation region for user
inhalation; an aerosol outlet tube, integrally formed with the
dividing wall element, to provide a portion of the air channel
between the aerosol generation region and the aerosol outlet.
76. The cartridge of claim 75, wherein the aerosol outlet tube
extends beyond the dividing wall in a direction towards the
mouthpiece end.
77. The cartridge of claim 75, wherein the dividing wall element is
made of a plastic material.
78. The cartridge of claim 75, wherein the dividing wall element is
made of polypropylene.
79. The cartridge of claim 75, wherein the dividing wall element
extends around the aerosol outlet tube.
80. The cartridge of claim 75, wherein the liquid transport element
comprises a capillary wick.
81. The cartridge of claim 75, wherein the heating element
comprises a heater.
82. The cartridge of claim 75, wherein the liquid transport element
and the heating element comprise a single integrated element.
83. The cartridge of claim 75, wherein the cartridge comprises at
least two contact electrodes mounted to the cartridge to allow
power to be supplied to the heating element.
84. The cartridge of claim 83, wherein at least one contact
electrode further comprises a flange portion which projects
outwardly around the contact electrode, wherein the flange portion
rests on a surface from the cartridge.
85. The cartridge of claim 84, wherein each flange portion has a
thickness of no more than 1 mm.
86. The cartridge of claim 83, wherein each contact electrode is
gold plated.
87. The cartridge of claim 83, wherein the cartridge comprises no
more than two contact electrodes.
88. An aerosol provision system of claim 75 and a control unit,
wherein the control unit comprises a cartridge receiving section
that includes an interface arranged to cooperatively engage with
the interface at the interface end of the cartridge so as to
releasably couple the cartridge to the control unit, wherein the
control unit further comprises a power supply and control circuitry
configured to selective supply power from the power supply to the
heating element in the cartridge via their cooperatively engaging
interfaces.
89. An aerosol provision system according to claim 88, wherein the
control unit comprises: an outer housing including a receptacle
wall that defines a receptacle having an open first end and a
second end, wherein the receptacle wall comprises at least one
opening; a body configured to be inserted inside the receptacle via
the open first end towards the second end, the body comprising a
protrusion, wherein the protrusion is configured to extend through
the opening when the body is fully inserted inside the receptacle;
wherein the control unit comprises at least one deformable portion
which is configured to deform as the body is inserted into the
receptacle to allow the body to be fully inserted into the
receptacle, and to allow the protrusion to extend through the
opening of the receptacle wall.
90. An aerosol provision system according to claim 89, wherein the
deformable portion is configured to elastically deform as the body
is inserted into the receptacle.
Description
PRIORITY CLAIM
[0001] The present application is a National Phase entry of PCT
Application No. PCT/GB2020/050376, filed Feb. 18, 2020, which
claims priority from Great Britain Application No. 1902220.1, filed
Feb. 18, 2019, each of which is hereby fully incorporated herein by
reference.
TECHNICAL FIELD
[0002] The present disclosure relates to aerosol provision systems
such as, but not limited to, nicotine delivery systems (e.g.
electronic cigarettes and the like).
BACKGROUND
[0003] Electronic aerosol provision systems such as electronic
cigarettes (e-cigarettes) generally contain an aerosol precursor
material, such as a reservoir of a source liquid containing a
formulation, typically but not necessarily including nicotine, or a
solid material such a tobacco-based product, from which an aerosol
is generated for inhalation by a user, for example through heat
vaporization. Thus, an aerosol provision system will typically
comprise a heating element, e.g. a heating element, arranged to
vaporize a portion of precursor material to generate an aerosol in
an aerosol generation region of an air channel through the aerosol
provision system. As a user inhales on the device and electrical
power is supplied to the heating element, air is drawn into the
device through one or more inlet holes and along the air channel to
the aerosol generation region, where the air mixes with the
vaporized precursor material and forms a condensation aerosol. The
air drawn through the aerosol generation region continues along the
air channel to a mouthpiece opening, carrying some of the aerosol
with it, and out through the mouthpiece opening for inhalation by
the user.
[0004] It is common for aerosol provision systems to comprise a
modular assembly, often having two main functional parts, namely a
control unit and disposable/replaceable cartridge part. Typically
the cartridge part will comprise the consumable aerosol precursor
material and the heating element (atomizer), while the control unit
part will comprise longer-life items, such as a rechargeable
battery, device control circuitry, activation sensors and user
interface features. The control unit may also be referred to as a
reusable part or battery section and the replaceable cartridge may
also be referred to as a disposable part or cartomizer.
[0005] The control unit and cartridge are mechanically coupled
together at an interface for use, for example using a screw thread,
bayonet, latched or friction fit fixing. When the aerosol precursor
material in a cartridge has been exhausted, or the user wishes to
switch to a different cartridge having a different aerosol
precursor material, the cartridge may be removed from the control
unit and a replacement cartridge may be attached to the device in
its place.
[0006] A potential drawbacks for cartridges containing liquid
aerosol precursor (e-liquid) is the risk of leakage. An e-cigarette
cartridge will typically have a mechanism, e.g. a capillary wick,
for drawing liquid from a liquid reservoir to a heating element
located in an air path/channel connecting from an air inlet to an
aerosol outlet for the cartridge. Because there is a fluid
transport path from the liquid reservoir into the open air channel
through the cartridge, there is a corresponding risk of liquid
leaking from the cartridge. Leakage is undesirable both from the
perspective of the end user naturally not wanting to get the
e-liquid on their hands or other items, and also from a reliability
perspective, since leakage from an end of the cartridge connected
to the control unit may damage the control unit, for example due to
corrosion. Some approaches to reduce the risk of leakage may
involve restricting the flow of liquid to the heating element, for
example by tightly clamping a wick where it enters the air channel,
but this can in some scenarios lead to a risk of insufficient
liquid being supplied to the heating element (dry-out), which can
give rise to overheating and undesirable flavors.
[0007] Various approaches are described herein which seek to help
address or mitigate some of the issues discussed above.
SUMMARY
[0008] According to a first aspect of certain embodiments there is
provided a cartridge for an aerosol provision system comprising the
cartridge and a control unit, wherein the cartridge comprises:
[0009] an air channel extending from an air inlet for the cartridge
to an aerosol outlet via a aerosol generation region;
[0010] a heating element for heating liquid from a reservoir to
generate aerosol in the aerosol generation region;
[0011] a valve located in the air channel upstream of the aerosol
generating region;
[0012] wherein the cartridge is configured such that air passing
through the air channel is configured to pass from the air inlet,
past the air valve, into the aerosol generating region, and then
out from the aerosol outlet.
[0013] According to a second aspect of certain embodiments there is
provided an aerosol provision system comprising the cartridge from
the first aspect and a control unit, wherein the control unit
comprises a cartridge receiving section that includes an interface
arranged to cooperatively engage with the cartridge so as to
releasably couple the cartridge to the control unit, wherein the
control unit further comprises a power supply and control circuitry
configured to selective supply power from the power supply to the
heating element in the cartridge via their cooperatively engaging
interfaces.
[0014] According to a third aspect of certain embodiments there is
provided a method of generating aerosol from a cartridge for an
aerosol provision system, wherein the cartridge comprises: [0015]
an aerosol outlet; [0016] an air channel extending from an air
inlet for the cartridge to the aerosol outlet via a aerosol
generation region; and [0017] a heating element for heating liquid
from a reservoir to generate aerosol in the aerosol generation
region;
[0018] a valve located in the air channel upstream of the aerosol
generating region; [0019] wherein the method comprises passing air
through the air channel from the air inlet, past the air valve,
into the aerosol generating region, and then out from the aerosol
outlet.
[0020] It will be appreciated that features and aspects of the
invention described above in relation to the various aspects of the
invention are equally applicable to, and may be combined with,
embodiments of the invention according to other aspects of the
invention as appropriate, and not just in the specific combinations
described herein.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] Embodiments of the invention will now be described, by way
of example only, with reference to the accompanying drawings, in
which:
[0022] FIG. 1 schematically represents in perspective view an
aerosol provision system comprising a cartridge and control unit
(shown separated) in accordance with certain embodiments of the
disclosure;
[0023] FIG. 2 schematically represents in exploded perspective view
of components of the cartridge of the aerosol provision system of
FIG. 1;
[0024] FIGS. 3A to 3C schematically represent various cross-section
views of a housing part of the cartridge of the aerosol provision
system of FIG. 1;
[0025] FIGS. 4A and 4B schematically represent a perspective view
and a plan view of a dividing wall element of the cartridge of the
aerosol provision system of FIG. 1;
[0026] FIGS. 5A to 5C schematically represent two perspective views
and a plan view of a resilient plug of the cartridge of the aerosol
provision system of FIG. 1;
[0027] FIGS. 6A and 6B schematically represent a perspective view
and a plan view of a bottom cap of the cartridge of the aerosol
provision system of FIG. 1;
[0028] FIG. 7 schematically represents as a cross section view a
modified cartridge for use with the control unit shown in FIG. 1 to
form an aerosol provision system in accordance with certain
embodiments of the disclosure;
[0029] FIG. 8 schematically represents as a cross section view a
portion of a cartridge for use with the control unit shown in FIG.
1 to form an aerosol provision system in accordance with certain
embodiments of the disclosure;
[0030] FIG. 9A schematically shows forming a crimped electrode in
accordance with certain embodiments of the disclosure;
[0031] FIG. 9B schematically shows forming a crimped electrode in
accordance with certain embodiments of the disclosure;
[0032] FIG. 9C schematically shows forming a crimped electrode in
accordance with certain embodiments of the disclosure;
[0033] FIG. 10A schematically shows a perspective view of an
interior for a control unit for use in an aerosol provision system
in accordance with certain embodiments of the disclosure; and
[0034] FIGS. 10B and 10C schematically shows a perspective view of
individual components from the components shown in FIG. 10A.
DETAILED DESCRIPTION OF THE DRAWINGS
[0035] Aspects and features of certain examples and embodiments are
discussed/described herein. Some aspects and features of certain
examples and embodiments may be implemented conventionally and
these are not discussed/described in detail in the interests of
brevity. It will thus be appreciated that aspects and features of
apparatus and methods discussed herein which are not described in
detail may be implemented in accordance with any conventional
techniques for implementing such aspects and features.
[0036] The present disclosure relates to non-combustible aerosol
provision systems, which may also be referred to as aerosol
provision systems, such as e-cigarettes. According to the present
disclosure, a "non-combustible" aerosol provision system is one
where a constituent aerosolizable material of the aerosol provision
system (or component thereof) is not combusted or burned in order
to facilitate delivery to a user. Aerosolizable material, which
also may be referred to herein as aerosol generating material or
aerosol precursor material, is material that is capable of
generating aerosol, for example when heated, irradiated or
energized in any other way.
[0037] Throughout the following description the term "e-cigarette"
or "electronic cigarette" may sometimes be used, but it will be
appreciated this term may be used interchangeably with aerosol
provision system/device and electronic aerosol provision
system/device. An electronic cigarette may also known as a vaping
device or electronic nicotine delivery system (END), although it is
noted that the presence of nicotine in the aerosolizable material
is not a requirement.
[0038] In some embodiments, the non-combustible aerosol provision
system is a hybrid system to generate aerosol using a combination
of aerosolizable materials, one or a plurality of which may be
heated. In some embodiments, the hybrid system comprises a liquid
or gel aerosolizable material and a solid aerosolizable material.
The solid aerosolizable material may comprise, for example, tobacco
or a non-tobacco product.
[0039] Typically, the non-combustible aerosol provision system may
comprise a non-combustible aerosol provision device and an article
for use with the non-combustible aerosol provision device. However,
it is envisaged that articles which themselves comprise a means for
powering an aerosol generating component may themselves form the
non-combustible aerosol provision system.
[0040] In some embodiments, the article for use with the
non-combustible aerosol provision device may comprise an
aerosolizable material (or aerosol precursor material), an aerosol
generating component (or vaporizer), an aerosol generating area, a
mouthpiece, and/or an area for receiving aerosolizable
material.
[0041] In some embodiments, the aerosol generating component is a
heater capable of interacting with the aerosolizable material so as
to release one or more volatiles from the aerosolizable material to
form an aerosol. In some embodiments, the aerosol generating
component is capable of generating an aerosol from the
aerosolizable material without heating. For example, the aerosol
generating component may be capable of generating an aerosol from
the aerosolizable material without applying heat thereto, for
example via one or more of vibrational, mechanical, pressurization
or electrostatic means.
[0042] In some embodiments, the substance to be delivered may be an
aerosolizable material which may comprise an active constituent, a
carrier constituent and optionally one or more other functional
constituents.
[0043] The active constituent may comprise one or more
physiologically and/or olfactory active constituents which are
included in the aerosolizable material in order to achieve a
physiological and/or olfactory response in the user. The active
constituent may for example be selected from nutraceuticals,
nootropics, and psychoactives. The active constituent may be
naturally occurring or synthetically obtained. The active
constituent may comprise for example nicotine, caffeine, taurine,
theine, a vitamin such as B6 or B12 or C, melatonin, a cannabinoid,
or a constituent, derivative, or combinations thereof. The active
constituent may comprise a constituent, derivative or extract of
tobacco or of another botanical. In some embodiments, the active
constituent is a physiologically active constituent and may be
selected from nicotine, nicotine salts (e.g. nicotine
ditartrate/nicotine bitartrate), nicotine-free tobacco substitutes,
other alkaloids such as caffeine, or mixtures thereof.
[0044] In some embodiments, the active constituent is an olfactory
active constituent and may be selected from a "flavor" and/or
"flavorant" which, where local regulations permit, may be used to
create a desired taste, aroma or other somatosensorial sensation in
a product for adult consumers. In some instances such constituents
may be referred to as flavors, flavorants, cooling agents, heating
agents, and/or sweetening agents. They may include naturally
occurring flavor materials, botanicals, extracts of botanicals,
synthetically obtained materials, or combinations thereof (e.g.,
tobacco, cannabis, licorice (liquorice), hydrangea, eugenol,
Japanese white bark magnolia leaf, chamomile, fenugreek, clove,
maple, matcha, menthol, Japanese mint, aniseed (anise), cinnamon,
turmeric, Indian spices, Asian spices, herb, wintergreen, cherry,
berry, red berry, cranberry, peach, apple, orange, mango,
clementine, lemon, lime, tropical fruit, papaya, rhubarb, grape,
durian, dragon fruit, cucumber, blueberry, mulberry, citrus fruits,
Drambuie, bourbon, scotch, whiskey, gin, tequila, rum, spearmint,
peppermint, lavender, aloe vera, cardamom, celery, cascarilla,
nutmeg, sandalwood, bergamot, geranium, khat, naswar, betel,
shisha, pine, honey essence, rose oil, vanilla, lemon oil, orange
oil, orange blossom, cherry blossom, cassia, caraway, cognac,
jasmine, ylang-ylang, sage, fennel, wasabi, piment, ginger,
coriander, coffee, hemp, a mint oil from any species of the genus
Mentha, eucalyptus, star anise, cocoa, lemongrass, rooibos, flax,
Ginkgo biloba, hazel, hibiscus, laurel, mate, orange skin, rose,
tea such as green tea or black tea, thyme, juniper, elderflower,
basil, bay leaves, cumin, oregano, paprika, rosemary, saffron,
lemon peel, mint, beefsteak plant, curcuma, cilantro, myrtle,
cassis, valerian, pimento, mace, damien, marjoram, olive, lemon
balm, lemon basil, chive, carvi, verbena, tarragon, limonene,
thymol, camphene), flavor enhancers, bitterness receptor site
blockers, sensorial receptor site activators or stimulators, sugars
and/or sugar substitutes (e.g., sucralose, acesulfame potassium,
aspartame, saccharine, cyclamates, lactose, sucrose, glucose,
fructose, sorbitol, or mannitol), and other additives such as
charcoal, chlorophyll, minerals, botanicals, or breath freshening
agents. They may be imitation, synthetic or natural ingredients or
blends thereof. They may be in any suitable form, for example,
liquid such as an oil, solid such as a powder, or gasone or more of
extracts (e.g., licorice, hydrangea, Japanese white bark magnolia
leaf, chamomile, fenugreek, clove, menthol, Japanese mint, aniseed,
cinnamon, herb, wintergreen, cherry, berry, peach, apple, Drambuie,
bourbon, scotch, whiskey, spearmint, peppermint, lavender,
cardamom, celery, cascarilla, nutmeg, sandalwood, bergamot,
geranium, honey essence, rose oil, vanilla, lemon oil, orange oil,
cassia, caraway, cognac, jasmine, ylang-ylang, sage, fennel,
piment, ginger, anise, coriander, coffee, or a mint oil from any
species of the genus Mentha), flavor enhancers, bitterness receptor
site blockers, sensorial receptor site activators or stimulators,
sugars and/or sugar substitutes (e.g., sucralose, acesulfame
potassium, aspartame, saccharine, cyclamates, lactose, sucrose,
glucose, fructose, sorbitol, or mannitol), and other additives such
as charcoal, chlorophyll, minerals, botanicals, or breath
freshening agents. They may be imitation, synthetic or natural
ingredients or blends thereof. They may be in any suitable form,
for example, oil, liquid, or powder.
[0045] In some embodiments, the flavor comprises menthol, spearmint
and/or peppermint. In some embodiments, the flavor comprises flavor
components of cucumber, blueberry, citrus fruits and/or redberry.
In some embodiments, the flavor comprises eugenol. In some
embodiments, the flavor comprises flavor components extracted from
tobacco. In some embodiments, the flavor may comprise a sensate,
which is intended to achieve a somatosensorial sensation which are
usually chemically induced and perceived by the stimulation of the
fifth cranial nerve (trigeminal nerve), in addition to or in place
of aroma or taste nerves, and these may include agents providing
heating, cooling, tingling, numbing effect. A suitable heat effect
agent may be, but is not limited to, vanillyl ethyl ether and a
suitable cooling agent may be, but not limited to eucalyptol,
WS-3.
[0046] The carrier constituent may comprise one or more
constituents capable of forming an aerosol. In some embodiments,
the carrier constituent may comprise one or more of glycerine,
glycerol, propylene glycol, diethylene glycol, triethylene glycol,
tetraethylene glycol, 1,3-butylene glycol, erythritol,
meso-Erythritol, ethyl vanillate, ethyl laurate, a diethyl
suberate, triethyl citrate, triacetin, a diacetin mixture, benzyl
benzoate, benzyl phenyl acetate, tributyrin, lauryl acetate, lauric
acid, myristic acid, and propylene carbonate.
[0047] The one or more other functional constituents may comprise
one or more of pH regulators, coloring agents, preservatives,
binders, fillers, stabilizers, and/or antioxidants.
[0048] As noted above, aerosol provision systems (e-cigarettes)
often comprise a modular assembly including both a reusable part
(control unit) and a replaceable (disposable) cartridge part.
Devices conforming to this type of two-part modular configuration
may generally be referred to as two-part devices. It is also common
for electronic cigarettes to have a generally elongate shape. For
the sake of providing a concrete example, certain embodiments of
the disclosure described herein comprise this kind of generally
elongate two-part device employing disposable cartridges. However,
it will be appreciated the underlying principles described herein
may equally be adopted for other electronic cigarette
configurations, for example modular devices comprising more than
two parts, as devices conforming to other overall shapes, for
example based on so-called box-mod high performance devices that
typically have a more boxy shape.
[0049] FIG. 1 is a schematic perspective view of an example aerosol
provision system/device (e-cigarette) 1 in accordance with certain
embodiments of the disclosure. Terms concerning the relative
location of various aspects of the electronic cigarette (e.g. terms
such as upper, lower, above, below, top, bottom etc.) are used
herein with reference to the orientation of the electronic
cigarette as shown in FIG. 1 (unless the context indicates
otherwise). However, it will be appreciated this is purely for ease
of explanation and is not intended to indicate there is any
required orientation for the electronic cigarette in use.
[0050] The e-cigarette 1 comprises two main components, namely a
cartridge 2 and a control unit 4. The control unit 4 and the
cartridge 2 are shown separated in FIG. 1, but are coupled together
when in use.
[0051] The cartridge 2 and control unit 4 are coupled by
establishing a mechanical and electrical connection between them.
The specific manner in which the mechanical and electrical
connection is established is not of primary significance to the
principles described herein and may be established in accordance
with conventional techniques, for example based around a screw
thread, bayonet, latched or friction-fit mechanical fixing with
appropriately arranged electrical contacts/electrodes for
establishing the electrical connection between the two parts as
appropriate. For example electronic cigarette 1 represented in FIG.
1, the cartridge comprises a mouthpiece end 52 and an interface end
54 and is coupled to the control unit by inserting an interface end
portion 6 at the interface end of the cartridge into a
corresponding receptacle 8/receiving section of the control unit.
The interface end portion 6 of the cartridge is a close fit to be
receptacle 8 and includes protrusions 56 which engage with
corresponding detents in the interior surface of a receptacle wall
12 defining the receptacle 8 to provide a releasable mechanical
engagement between the cartridge and the control unit. An
electrical connection is established between the control unit and
the cartridge via a pair of electrical contacts on the bottom of
the cartridge (not shown in FIG. 1) and corresponding sprung
contact pins in the base of the receptacle 8 (not shown in FIG. 1).
As noted above, the specific manner in which the electrical
connection is established is not significant to the principles
described herein, and indeed some implementations might not have an
electrical connection between the cartridge and a control unit at
all, for example because the transfer of electrical power from the
reusable part to the cartridge may be wireless (e.g. based on
electromagnetic induction techniques).
[0052] The electronic cigarette 1 has a generally elongate shape
extending along a longitudinal axis L. When the cartridge is
coupled to the control unit, the overall length of the electronic
cigarette in this example (along the longitudinal axis) is around
12.5 cm. The overall length of the control unit is around 9 cm and
the overall length of the cartridge is around 5 cm (i.e. there is
around 1.5 cm of overlap between the interface end portion 6 of the
cartridge and the receptacle 8 of the control unit when they are
coupled together). The electronic cigarette has a cross-section
which is generally oval and which is largest around the middle of
the electronic cigarette and tapers in a curved manner towards the
ends. The cross-section around the middle of the electronic
cigarette has a width of around 2.5 cm and a thickness of around
1.7 cm. The end of the cartridge has a width of around 2 cm and a
thickness of around 0.6 mm, whereas the other end of the electronic
cigarette has a width of around 2 cm and a thickness of around 1.2
cm. The outer housing of the electronic cigarette is in this
example is formed from plastic. It will be appreciated the specific
size and shape of the electronic cigarette and the material from
which it is made is not of primary significance to the principles
described herein and may be different in different implementations.
That is to say, the principles described herein may equally be
adopted for electronic cigarettes having different sizes, shapes
and/or materials.
[0053] The control unit 4 may in accordance with certain
embodiments of the disclosure be broadly conventional in terms of
its functionality and general construction techniques. In the
example of FIG. 1, the control unit 4 comprises a plastic outer
housing 10 including the receptacle wall 12 that defines the
receptacle 8 for receiving the end of the cartridge as noted above.
The outer housing 10 of the control unit 4 in this example has a
generally oval cross section conforming to the shape and size of
the cartridge 2 at their interface to provide a smooth transition
between the two parts. The receptacle 8 and the end portion 6 of
the cartridge 2 are symmetric when rotated through 180.degree. so
the cartridge can be inserted into the control unit in two
different orientations. The receptacle wall 12 includes two control
unit air inlet openings 14 (i.e. holes in the wall). These openings
14 are positioned to align with an air inlet 50 for the cartridge
when the cartridge is coupled to the control unit. A different one
of the openings 14 aligns with the air inlet 50 of the cartridge in
the different orientations. It will be appreciated some
implementations may not have any degree of rotational symmetry such
that the cartridge is couplable to the control unit in only one
orientation while other implementations may have a higher degree of
rotational symmetry such that the cartridge is couplable to the
control unit in more orientations.
[0054] The control unit further comprises a battery 16 for
providing operating power for the electronic cigarette, control
circuitry 18 for controlling and monitoring the operation of the
electronic cigarette, a user input button 20, an indicator light
22, and a charging port 24.
[0055] The battery 16 in this example is rechargeable and may be of
a conventional type, for example of the kind normally used in
electronic cigarettes and other applications requiring provision of
relatively high currents over relatively short periods. The battery
16 may be recharged through the charging port 24, which may, for
example, comprise a USB connector.
[0056] The input button 20 in this example is a conventional
mechanical button, for example comprising a sprung mounted
component which may be pressed by a user to establish an electrical
contact in underlying circuitry. In this regard, the input button
may be considered an input device for detecting user input, e.g. to
trigger aerosol generation, and the specific manner in which the
button is implemented is not significant. For example, other forms
of mechanical button or touch-sensitive button (e.g. based on
capacitive or optical sensing techniques) may be used in other
implementations, or there may be no button and the device may rely
on a puff detector for triggering aerosol generation.
[0057] The indicator light 22 is provided to give a user with a
visual indication of various characteristics associated with the
electronic cigarette, for example, an indication of an operating
state (e.g. on/off/standby), and other characteristics, such as
battery life or fault conditions. Different characteristics may,
for example, be indicated through different colors and/or different
flash sequences in accordance with generally conventional
techniques.
[0058] The control circuitry 18 is suitably configured/programmed
to control the operation of the electronic cigarette to provide
conventional operating functions in line with the established
techniques for controlling electronic cigarettes. The control
circuitry (processor circuitry) 18 may be considered to logically
comprise various sub-units/circuitry elements associated with
different aspects of the electronic cigarette's operation. For
example, depending on the functionality provided in different
implementations, the control circuitry 18 may comprises power
supply control circuitry for controlling the supply of power from
the battery to the cartridge in response to user input, user
programming circuitry for establishing configuration settings (e.g.
user-defined power settings) in response to user input, as well as
other functional units/circuitry associated functionality in
accordance with the principles described herein and conventional
operating aspects of electronic cigarettes, such as indicator light
display driving circuitry and user input detection circuitry. It
will be appreciated the functionality of the control circuitry 18
can be provided in various different ways, for example using one or
more suitably programmed programmable computer(s) and/or one or
more suitably configured application-specific integrated
circuit(s)/circuitry/chip(s)/chipset(s) configured to provide the
desired functionality.
[0059] FIG. 2 is an exploded schematic perspective view of the
cartridge 2 (exploded along the longitudinal axis L). The cartridge
2 comprises a housing part 32, an air channel seal 34, a dividing
wall element 36, an outlet tube 38, a heating element 40, a liquid
transport element 42, a plug 44, and an end cap 48 with contact
electrodes 46. FIGS. 3 to 6 schematically represents some of these
components in more detail.
[0060] FIG. 3A is a schematic cut-away view of the housing part 32
through the longitudinal axis L where the housing part 32 is
thinnest. FIG. 3B is a schematic cut-away view of the housing part
32 through the longitudinal axis L where the housing part 32 is
widest. FIG. 3C is a schematic view of the housing part along the
longitudinal axis L from the interface end 54 (i.e. viewed from
below in the orientation of FIGS. 3A and 3B).
[0061] FIG. 4A is a schematic perspective view of the dividing wall
element 36 as seen from below. FIG. 4B is a schematic cross-section
through an upper part of the dividing wall element 36 as viewed
from below.
[0062] FIG. 5A is a schematic perspective view of the plug 44 from
above and FIG. 5B is a schematic perspective view of the plug 44
from below. FIG. 5C is a schematic view of the plug 44 along the
longitudinal axis L seen from the mouthpiece end 52 of the
cartridge (i.e. viewed from above for the orientation in FIGS. 1
and 2).
[0063] FIG. 6A is a schematic perspective view of the end cap 48
from above. FIG. 6B is a schematic view of the end cap 48 along the
longitudinal axis L seen from the mouthpiece end 52 of the
cartridge (i.e. from above).
[0064] The housing part 32 in this example comprises a housing
outer wall 64 and a housing inner tube 62 which in this example are
formed from a single molding of polypropylene. The housing outer
wall 64 defines the external appearance of the cartridge 2 and the
housing inner tube 62 defines a part the air channel through the
cartridge. The housing part is open at the interface end 54 of the
cartridge and closed at the mouthpiece end 52 of the cartridge
except for a mouthpiece opening/aerosol outlet 60 in fluid
communication with the housing inner tube 62. The housing part 32
includes an opening in a sidewall which provides the air inlet 50
for the cartridge. The air inlet 50 in this example has an area of
around 2 mm.sup.2. The outer surface of the outer wall 64 of the
housing part 32 includes the protrusions 56 discussed above which
engage with corresponding detents in the interior surface of the
receptacle wall 12 defining the receptacle 8 to provide a
releasable mechanical engagement between the cartridge and the
control unit. The inner surface of the outer wall 64 of the housing
part includes further protrusions 66 which act to provide an
abutment stop for locating the dividing wall element 36 along the
longitudinal axis L when the cartridge is assembled. The outer wall
64 of the housing part 32 further comprises holes which provide
latch recesses 68 arranged to receive corresponding latch
projections 70 in the end cap to fix the end cap to be housing part
when the cartridge is assembled.
[0065] The outer wall 64 of the housing part 32 includes a
double-walled section 74 that defines a gap 76 in fluid
communication with the air inlet 50. The gap 76 provides a portion
of the air channel through the cartridge. In this example the
doubled-walled section 74 of the housing part 32 is arranged so the
gap defines an air channel running within the housing outer wall 64
parallel to the longitudinal axis with a cross-section in a plane
perpendicular to the longitudinal axis of around 3 mm.sup.2. The
gap/portion of air channel 76 defined by the double-walled section
of the housing part extends down to the open end of the housing
part 32.
[0066] The air channel seal 34 is a silicone molding generally in
the form of a tube having a through hole 80. The outer wall of the
air channel seal 34 includes circumferential ridges 84 and an upper
collar 82. The inner wall of the air channel seal 34 also includes
circumferential ridges, but these are not visible in FIG. 2. When
the cartridge is assembled the air channel seal 34 is mounted to
the housing inner tube 62 with an end of the housing inner tube 62
extending partly into the through hole 80 of the air channel seal
34. The through hole 80 in the air channel seal has a diameter of
around 5.8 mm in its relaxed state whereas the end of the housing
inner tube 62 has a diameter of around 6.2 mm so that a seal is
formed when the air channel seal 34 is stretched to accommodate the
housing inner tube 62. This seal is facilitated by the ridges on
the inner surface of the air channel seal 34.
[0067] The outlet tube 38 comprises a tubular section of ANSI 304
stainless steel with an internal diameter of around 8.6 mm and a
wall thickness of around 0.2 mm. The bottom end of the outlet tube
38 includes a pair of diametrically opposing slots 88 with an end
of each slot having a semi-circular recess 90. When the cartridge
is assembled the outlet tube 38 mounts to the outer surface of the
air channel seal 34. The outer diameter of the air channel seal is
around 9.0 mm in its relaxed state so that a seal is formed when
the air channel seal 34 is compressed to fit inside the outlet tube
38. This seal is facilitated by the ridges 84 on the outer surface
of the air channel seal 34. The collar 80 on the air channel seal
34 provides a stop for the outlet tube 38.
[0068] The liquid transport element 42 comprises a capillary wick
and the heating element 40 comprises a resistance wire heater wound
around the capillary wick. In addition to the portion of the
resistance wire wound around the capillary wick, the heating
element comprises electrical leads 41 which pass through holes in
the plug 44 to contact electrodes 46 mounted to the end cap 54 to
allow power to be supplied to the heating element via the
electrical interface the established when the cartridge is
connected to a control unit. The heating element leads 41 may
comprise the same material as the resistance wire wound around the
capillary wick, or may comprise a different material (e.g.
lower-resistance material) connected to the resistance wire wound
around the capillary wick. In this example the heater coil 40
comprises a nickel iron alloy wire and the wick 42 comprises a
glass fiber bundle. The heating element and liquid transport
element may be provided in accordance with any conventional
techniques and is may comprise different forms and/or different
materials. For example, in some implementations the wick may
comprise fibrous or solid a ceramic material and the heater may
comprise a different alloy. In other examples the heater and wick
may be combined, for example in the form of a porous and a
resistive material. More generally, it will be appreciated the
specific nature liquid transport element and heating element is not
of primary significance to the principles described herein.
[0069] When the cartridge is assembled, the wick 42 is received in
the semi-circular recesses 90 of the outlet tube 38 so that a
central portion of the wick about which the heating coil is would
is inside the outlet tube while end portions of the wick are
outside the outlet tube 38.
[0070] The plug 44 in this example comprises a single molding of
silicone, may be resilient. The plug comprises a base part 100 with
an outer wall 102 extending upwardly therefrom (i.e. towards the
mouthpiece end of the cartridge). The plug further comprises an
inner wall 104 extending upwardly from the base part 100 and
surrounding a through hole 106 through the base part 100.
[0071] The outer wall 102 of the plug 44 conforms to an inner
surface of the housing part 32 so that when the cartridge is
assembled the plug in 44 forms a seal with a the housing part 32.
The inner wall 104 of the plug 44 conforms to an inner surface of
the outlet tube 38 so that when the cartridge is assembled the plug
44 also forms a seal with the outlet tube 38. The inner wall 104
includes a pair of diametrically opposing slots 108 with the end of
each slot having a semi-circular recess 110. Extended outwardly
(i.e. in a direction away from the longitudinal axis of the
cartridge) from the bottom of each slot in the inner wall 104 is a
cradle section 112 shaped to receive a section of the liquid
transport element 42 when the cartridge is assembled. The slots 108
and semi-circular recesses 110 provided by the inner wall of the
plug 44 and the slots 88 and semi-circular recesses 90 of the
outlet tube 38 are aligned so that the slots 88 in the outlet tube
38 accommodate respective ones of the cradles 112 with the
respective semi-circular recesses in the outlet tube and plug
cooperating to define holes through which the liquid transport
element passes. The size of the holes provided by the semi-circular
recesses through which the liquid transport element passes
correspond closely to the size and shape of the liquid transport
element, but are slightly smaller so a degree of compression is
provided by the resilience of the plug 44. This allows liquid to be
transported along the liquid transport element by capillary action
while restricting the extent to which liquid which is not
transported by capillary action can pass through the openings. As
noted above, the plug 44 includes further openings 114 in the base
part 100 through which the contact leads 41 for the heating element
pass when the cartridge is assembled. The bottom of the base part
of the plug includes spacers 116 which maintain an offset between
the remaining surface of the bottom of the base part and the end
cap 48. These spacers 116 include the openings 114 through which
the electrical contact leads 41 for the heating element pass.
[0072] The end cap 48 comprises a polypropylene molding with a pair
of gold-plated copper electrode posts 46 mounted therein.
[0073] The ends of the electrode posts 44 on the bottom side of the
end cap are close to flush with the interface end 54 of the
cartridge provided by the end cap 48. These are the parts of the
electrodes to which correspondingly aligned sprung contacts in the
control unit connect when the cartridge is assembled and connected
to the control unit. The ends of the electrode posts on the inside
of the cartridge extend away from the end cap 48 and into the holes
114 in the plug 44 through which the contact leads 41 pass. The
electrode posts are slightly oversized relative to the holes 114
and include a chamfer at their upper ends to facilitate insertion
into the holes 114 in the plug where they are maintained in pressed
contact with the contact leads for the heating element by virtue of
the plug.
[0074] The end cap has a base section 124 and an upstanding wall
120 which conforms to the inner surface of the housing part 32. The
upstanding wall 120 of the end cap 48 is inserted into the housing
part 32 so the latch projections 70 engage with the latch recesses
68 in the housing part 32 to snap-fit the end cap 48 to the housing
part when the cartridge is assembled. The top of the upstanding
wall 120 of the end cap 48 abuts a peripheral part of the plug 44
and the lower face of the spacers 116 on the plug also abut the
base section 124 of the plug so that when the end cap 48 is
attached to the housing part it presses against the resilient part
44 to maintain it in slight compression.
[0075] The base portion 124 of the end cap 48 includes a peripheral
lip 126 beyond the base of the upstanding wall 112 with a thickness
which corresponds with the thickness of the outer wall of the
housing part at the interface end of the cartridge. The end cap
also includes an upstanding locating pin 122 which aligns with a
corresponding locating hole 128 in the plug to help establish their
relative location during assembly.
[0076] The dividing wall element 36 comprises a single molding of
polypropylene and includes a dividing wall 130 and a collar 132
formed by projections from the dividing wall 130 in the direction
towards the interface end of the cartridge. The dividing wall
element 36 has a central opening 134 through which the outlet tube
38 passes (i.e. the dividing wall is arranged around the outlet
tube 38). When the cartridge is assembled, the upper surface of the
outer wall 102 of the plug 44 engages with the lower surface of the
dividing wall 130, and the upper surface of the dividing wall 130
in turn engages with the projections 66 on the inner surface of the
outer wall 64 of the housing part 32. Thus, the dividing wall 130
prevents the plug from being pushed too far into the housing part
32--i.e. the dividing wall 130 is fixedly located along the
longitudinal axis of the cartridge by the protrusions 66 in the
housing part and so provides the plug with a fixed surface to push
against. The collar 132 formed by projections from the dividing
wall includes a first pair of opposing projections/tongues 134
which engage with corresponding recesses on an inner surface of the
outer wall 102 of the plug 44. The protrusions from the dividing
wall 130 further provide a pair of cradle sections 136 configured
to engage with corresponding ones of the cradle sections 112 in the
part 44 when the cartridge is assembled to further define the
opening through which the liquid transport element passes.
[0077] When the cartridge is assembled an air channel extending
from the air inlet 50 to the aerosol outlet 60 through the
cartridge is formed. Starting from the air inlet 50 in the side
wall of the housing part 32, a first section of the air channel is
provided by the gap 76 formed by the double-walled section 74 in
the outer wall 64 of the housing part 32 and extends from the air
inlet 50 towards the interface end 54 of the cartridge and past the
plug 44. A second portion of the air channel is provided by the gap
between the base of the plug 44 and the end cap 48. A third portion
of the air channel is provided by the hole 106 through the plug 44.
A fourth portion of the air channel is provided by the region
within the inner wall 104 of the plug and the outlet tube around
the heating element 40. This fourth portion of the air channel may
also be referred to as an aerosol/aerosol generation region, it
being the primary region in which aerosol is generated during use.
The air channel from the air inlet 50 to the aerosol generation
region may be referred to as an air inlet section of the air
channel. A fifth portion of the air channel is provided by the
remainder of the outlet tube 38. A sixth portion of the air channel
is provided by the outer housing inner tube 62 which connects the
air channel to the aerosol outlet 60. The air channel from the
aerosol generation region to be the aerosol outlet may be referred
to as an aerosol outlet section of the air channel.
[0078] Also, when the cartridge is assembled a reservoir for liquid
is formed by the space outside the air channel and inside the
housing part 32. This may be filled during manufacture, for example
through a filling hole which is then sealed, or by other means. The
specific nature of the liquid, for example in terms of its
composition, is not of primary significance to the principles
described herein, and in general any conventional liquid of the
type normally used in electronic cigarettes may be used. The
reservoir is closed at the interface end of the cartridge by the
plug 44. The reservoir includes a first region above the dividing
wall 130 and a second region below the dividing wall 130 within the
space formed between the air channel and the outer wall of the
plug. The liquid transport element (capillary wick) 42 passes
through openings in the wall of the air channel provided by the
semi-circular recesses 108, 90 in the plug 44 and the outlet tube
38 and the cradle sections 112, 136 in the plug 44 and the dividing
wall element 36 that engage with one another as discussed above.
Thus, the ends of the liquid transport element extend into the
second region of the reservoir from which they draw liquid through
the openings in the air channel to the heating element 40 for
subsequent vaporization.
[0079] In normal use, the cartridge 2 is coupled to the control
unit 4 and the control unit activated to supply power to the
cartridge via the contact electrodes 46 in the end cap 48. Power
then passes through the connection leads 41 to the heating element
40. The heating element is thus electrically heated and so
vaporizes a portion of the liquid from the liquid transport element
in the vicinity of the heating element. This generates aerosol in
the aerosol generation region of the air path. Liquid that is
vaporized from the liquid transport element is replaced by more
liquid drawn from the reservoir by capillary action. While the
heating element is activated, a user inhales on the mouthpiece end
52 of the cartridge. This causes air to be drawn through whichever
control unit air inlet 14 aligns with the air inlet 50 of the
cartridge (which will depend on the orientation in which the
cartridge was inserted into the control unit receptacle 8). Air
then enters the cartridge through the air inlet 50, passes along
the gap 76 in the double-walled section 74 of the housing part 32,
passes between the plug 44 and the end cap 48 before entering the
aerosol generation region surrounding the heating element 40
through the hole 106 in the base part 100 of the plug 44. The
incoming air mixes with aerosol generated from the heating element
to form a condensation aerosol, which is then drawn along the
outlet tube 38 and the housing part inner 62 before exiting through
the mouthpiece outlet/aerosol outlet 60 for user inhalation.
[0080] With reference to FIG. 7, there is shown schematically a
cross section view of a modified cartridge 200 for use with the
control unit 4 shown in FIG. 1 to form an aerosol provision system
in accordance with certain embodiments of the disclosure. The
cartridge 200 shown in FIG. 7 is based on the construction of the
cartridge 2 shown in FIGS. 1-6B, and comprises similar components
as set out by the reference numerals that are common to both sets
of Figures.
[0081] With reference to the cartridge 200 shown in FIG. 7, a first
modification over the cartridge 2 shown in FIGS. 1-6B is the
introduction of a valve 205 located in the air channel upstream of
the aerosol generation region (i.e. the region within the inner
wall 104 of the plug 44 and the outlet tube 38 around the heating
element 40). The function of the valve 205 is to allow air to pass
into aerosol generation region upon a user inhalation at the
mouthpiece outlet/aerosol outlet 60, but inhibit aerosol generated
inside the aerosol generating region from flowing through the air
channel back towards the air inlet 50 and/or down into the second
portion of the air channel provided by the gap between the base of
the plug 44 and the end cap 48. Preferably the valve is any type of
one-way valve of a suitable size and operating characteristic for
the particular cartridge 200. In some embodiments, the valve may be
a reed valve or a duckbill valve.
[0082] In accordance with some embodiments, the valve 205 may be
integrally formed with the plug 44. In this way, as opposed to
having the valve 205 formed as a separate component to the plug 44,
the overall number of separate components in the cartridge 200 can
be reduced. As shown in FIG. 7, in some cases the valve 205 may
taper inwardly in a direction extending away from the interface
end, and such that it tapers inwardly inside the aerosol generating
region. In this way any aerosol condensing on the valve 205 itself
may slide off the valve, which better ensures the valve remains
fully operational. In some embodiments, to ensure the momentum of
air is preserved as it passes through the cartridge 200, the valve
205 may be orientated inside the cartridge such that the air
passing through the valve 205 extends in a direction which is
substantially parallel to the direction of aerosol passing through
the aerosol outlet 60.
[0083] A second modification in the cartridge 200 shown in FIG. 7
over the cartridge 2 shown in FIGS. 1-6B is integrally forming the
outlet tube 38 with the dividing wall element 36, to provide a
portion of the air channel between the aerosol generation region
and the aerosol outlet 60. By integrally forming these two
components together as one, this reduces the overall component
count in the cartridge 200. In some embodiments of this modified
cartridge 200, the dividing wall element (which includes the
dividing wall 130) along with the outlet tube 38 may be made of a
plastic material, such as polypropylene.
[0084] A third modification to the cartridge 2 shown in FIGS. 1-6B
is shown best with reference to FIG. 8, which shows a sectional
view of a contact electrode 46 situated in the plug 44 and in the
end cap 48 of the cartridge. In the case of FIG. 8, a recess 225
extends down from the top surface of the contact electrode 46 and
accommodates a portion of the electrical lead 41 which provides
power between the contact electrode and the heating element 40. To
secure the portion electrical lead 41 located inside the recess
225, the contact electrode 46 may be crimped around the portion of
the heating element lead 41. Exemplary crimping operations will be
described in further detail with reference to FIGS. 9A-9C. In the
embodiment shown in FIG. 8, a portion of the contact electrode 46
may define a knurled outer surface 230 which is embedded in a
portion of the cartridge for securing the contact electrode to the
cartridge. In the case of FIG. 8, the knurled outer surface 230 is
located at the interface of the contact electrode 46 with the plug
44. In the embodiments where the plug 44 is injection molded around
the contact electrode 46, by introducing the knurled outer surface
230, this provides a greater surface area and thus a better
adhesion force between the two components. In some embodiments,
each contact electrode 46 may comprise a flange portion 235 which
projects outwardly around the contact electrode 46, wherein the
flange portion rests on a surface from the cartridge. Depending on
the presence or not of the end cap 48, the flange portion 235 may
rest on an end surface of the end cap 48, or on an end surface of
the plug 44, (the end surface in each case being proximal the
interface end of the cartridge). The presence of the flange portion
235 helps to support the contact electrode with respect to the plug
44, and also allows tools to more easily handle the contact
electrode 46 during the forming process of the cartridge 200. The
thickness of the flange portion will vary depending on the
particular shape of cartridge 200, but in some embodiments may be
less than 1 mm.
[0085] In the case of the contact electrode shown in in FIG. 8, the
shape of the contact electrode 46 is such that contact electrode
may be formed by a stamping process.
[0086] To provide a good conductive surface for each contact
electrode, which is also less prone to corrosion in the event of
ingress of aerosol/liquid contained elsewhere in the cartridge 200,
each contact electrode 46 may be gold plated.
[0087] With reference to FIGS. 9A-9C, there is described various
arrangements for forming a crimped contact electrode (such as the
contact electrode 46).
[0088] In each of the embodiments of FIG. 9A-9C there is shown a
first crimping member 240 and a second crimping member 245 which
are configured to be moved together in a depth direction to crimp a
heating element lead 41 and a contact electrode 46, placed between
the two crimping members, together. Each crimping member comprises
a contact face 250 which extends across the width and the height of
the crimping member, and the heating element lead 41 and the
contact electrode 46 are placed concentrically between these two
contact faces (the heating element lead 41 being placed within the
recess 225 of the contact electrode 46). In the embodiment of FIG.
9A, the contact faces 250 are brought together in a depth direction
perpendicular to the width and height of the first and second
crimping members such that the contact electrode is deformed
between the two contact faces and is crimped around the heating
element lead 41. As a result of this crimping process, small voids
(exaggerated in the above-right portion of FIG. 9A) may be created
between the outside surface area of the heating element lead 41 and
the contact electrode 46.
[0089] In some embodiments, located in the contact face 250 of the
first crimping member 240 is a first recess 255 extending across
the height of the crimping member and extending across a portion of
the width of the crimping member. A corresponding second recess 260
is located in the contact face 250 of the second crimping member
245 such that the second recess extends across the height of the
second crimping member and extends across a portion of the width of
the second crimping member. In such embodiments, the heating
element lead 41 and the contact electrode 46 are located between
the two recesses 255;260 such that when the contact faces are
brought together, the recesses crimp the contact electrode into a
shape corresponding to the shape of the recesses 255;260
[0090] In some embodiments, such as FIG. 9B, the first recess is a
first semi cylindrical recess, and the second recess is a second
semi cylindrical recess. When the contact faces are engaged
together, the two semi cylindrical recesses combine to form a
cylindrical recess which extends in the height direction.
[0091] In other embodiments, such as FIG. 9C, the first recess is a
first T-shaped recess, and the second recess is a second T-shaped
recess. When the contact faces are engaged together, the two
T-shaped recesses combine to form a recess having a plus-shaped
cross section. Each T-shaped recess is defined by an elongate
shoulder portion 265 which extends in the width direction of the
crimping member in which the T-shaped recess is located, and an
elongate leg portion 270 which extends perpendicular to the
shoulder portion 265 in the depth direction of the crimping member.
The edges from the first and/or second T-shaped recess which extend
across the height of the corresponding crimping member may be
chamfered (as shown in FIG. 9C).
[0092] With the provision of such recesses in the contact faces
250, this may reduce the extent of void formation between the
outside surface area of the heating element lead 41 and the contact
electrode 46 after the crimping process is complete. In some
embodiments, after the crimping process, the extent of voids
between the heating element lead 41 and the contact electrodes is
such that at least 50%, at least 60%, at least 70%, at least 80%,
at least 90% or at least 95% of the portion of the outside surface
area of each heating element lead 41 which is located within the
recess 225 of the contact electrode 46 is in contact with the
contact electrode.
[0093] To impede axial slip of the heating element lead 41 with
respect to the contact electrode 46, some or all of the recesses
255;260 from the contact faces 250 may comprise a protrusion 275
extending towards the contact face 250 of the crimping member in
which the recess is located, wherein the protrusion 275 does not
extend across the complete height of the recess. In some
embodiments, the protrusion 275 may be located midway along the
height of the recess in which the protrusion is located. In the
embodiments where a T-shaped recess is employed, the protrusion 275
may be located at an end of the elongate leg portion 270. The size
of any such protrusion 275 will depend on the application for the
crimped component, however in some embodiments the maximum height
of the protrusion may be no more than 5 mm.
[0094] With regards to other dimensions for the crimping members
240;245, in some embodiments the maximum height of each recess may
be less than 30 mm; the maximum depth of each recess may be no more
than 25 mm; and/or the maximum width of each recess may be no more
than 50 mm.
[0095] Turning to FIGS. 10A-10C, these relate to an interior for a
control unit 4 for use in an aerosol provision system in accordance
with certain embodiments of the disclosure. In the case of these
Figures, outlined in dotted form in FIG. 10A is the outer housing
10 shown in FIG. 1 including the receptacle wall 12 that defines a
receptacle 8 having an open first end and a second end. A body 280
is configured to be inserted inside the receptacle 8 via the open
first end towards the second end. The body 280 is configured to
hold the battery 16 and the control circuitry 18 as described in
connection with FIG. 1. The body further comprises at least two
contact electrodes 290, wherein each contact electrode 290 extends
through a respective opening 295 in the body 280. Once the body 280
is located in the receptacle 8, and the cartridge 2 is at least
partially within the receptacle 8, the contact electrodes 290 make
contact with the corresponding contact electrodes 46 from the
cartridge 2.
[0096] Located on the body 280 is a protrusion, in the form of the
input button 20, which is configured to extend through a
corresponding opening in the receptacle wall 12 from the outer
housing 10 when the body 280 is fully inserted inside the
receptacle 8. The control unit 4 comprises at least one deformable
portion 300 which is configured to deform as the body 280 is
inserted into the receptacle 8 to allow the body 280 to be fully
inserted into the receptacle 8, and to allow the protrusion (input
button 20) to extend through the opening of the receptacle wall 12.
In some embodiments, the deformation may be elastic
deformation.
[0097] In the case of the embodiment shown in FIGS. 10A-10C, the
body 280 comprises a slot 305 defining a cantilevered portion for
the body 280, such that the cantilevered portion forms the
deformable portion 300. The slot and/or the cantilevered portion
may be situated anywhere on the control unit 4 as necessary to
allow the input button 20 to deflect inwardly such that it and the
body 280 can be passed down through the receptacle 8 via the open
first end. In the embodiment shown in FIGS. 10A-10C, the body
comprises a plate portion 310 on which is located the input button
20 and the slot 305. In that arrangement, extending around a
portion of the input button 20 is the slot 305, such that the input
button 20 is located on the cantilevered portion.
[0098] By virtue of the control unit 4 comprising the deformable
portion 300, this allows the body to comprise an integral seal 310
which is located at the end of the body 280 more proximal the open
first end than the second end of the receptacle 8 when the body 280
is fully inserted inside the receptacle 8. That is as opposed to a
seal which is not integral, i.e. a separate seal which can only be
attached to the body 280 once the body 280 has been fully inserted
inside the receptacle 8, and after the input button 20 extends
through the opening in the receptacle wall 12.
[0099] Thus in accordance with certain embodiments of the
disclosure, a cartridge for an aerosol provision system may
generally comprise a housing part having a mouthpiece end and an
interface end, wherein the mouthpiece end includes an aerosol
outlet for the cartridge and the interface end includes an
interface for coupling the cartridge to a control unit. An air
channel wall (which may be formed by various components of the
cartridge) extends from an air inlet for the cartridge to the
aerosol outlet via an aerosol generation region in the vicinity of
a heating element. The cartridge has a reservoir within the housing
part containing liquid for aerosolization. The reservoir is defined
by a region within the housing part which is outside the air
channel and an end of the reservoir at the interface end of the
housing part is sealed by a resilient plug comprising a base part
and an outer wall, wherein the outer wall of the resilient plug
forms a seal with an inner surface of the housing part. Respective
ends of a liquid transport element pass through opening in the air
channel or into the reservoir so as to convey liquid from the
reservoir to the heating element.
[0100] One aspect of some particular cartridge configurations in
accordance with certain embodiments of the disclosure is the manner
in which the resilient plug 44 provides a seal to the housing part
32. In particular, in accordance with some example implementations
the outer wall 102 of the resilient plug 44 which seals to the
inner surface of the housing part 32 to form the end of the liquid
reservoir extends in direction parallel to the longitudinal axis of
the cartridge to a position which is further from the interface end
of the cartridge than the liquid transport element/heating element.
That is to say, the ends of the liquid transport element extends
into the liquid reservoir in a region which is surrounded by the
outer sealing wall of the resilient plug. Not only does this help
seal the reservoir against leakage, it allows the geometry of the
reservoir in the region which supplies the liquid transport element
with liquid to be governed by the geometry of the resilient plug.
For example, the radial thickness of the reservoir in this region
can readily be made smaller than the radial thickness in other
longitudinal positions along the air channel, which can help trap
liquid in the vicinity of the liquid transport element, thereby
helping to reduce the risk of dry out for different orientations of
the cartridge during use.
[0101] The outer wall of the resilient plug may, for example,
contact the inner surface of the housing part at locations over a
distance of at least 5 mm, 6 mm, 7 mm, 8 mm, 9 mm and 10 mm in a
direction extending from the interface end to the mouthpiece end
(i.e. parallel to the longitudinal axis). The outer wall of the
resilient plug may be in contact with the inner surface of the
housing over the majority of this distance, or the outer wall of
the resilient plug may include a number of (e.g. four)
circumferential ridges 140 to help improve sealing. The resilient
plug may be slightly oversized relative to the opening in the
housing part so that it is biased into slight compression. For
example, for the implementation shown in FIG. 3B, the interior
width of the housing part into which the resilient plug is inserted
in the plane of this figure is around 17.5 mm, whereas the
corresponding width of the resilient plug is around 18 mm, thereby
placing the resilient plug into compression when inserted into the
housing part. As can be most readily seen in FIGS. 5A to 5C,
whereas the outer cross section of the cartridge housing part is
symmetric under a 180.degree. rotation, the resilient plug 44 does
not have the same symmetry because it includes a flat 142 on one
side to accommodate the air channel gap 76 provided by the
double-walled section 74 of the housing part (i.e. the resilient
plug is asymmetric in a plane perpendicular to a longitudinal axis
of the cartridge to accommodate the double-walled section of the
housing part).
[0102] In terms of the radial size/width of the reservoir in the
annular region where the liquid transport element extends into the
reservoir, a distance between the air channel wall and the outer
wall of the resilient plug in this region may, for example, be in
the range 3 mm to 8 mm. In the example cartridge discussed above
which has a generally oval housing part and a generally circular
air channel, it will be appreciated the thickness of the reservoir
is different at different locations around the air channel. In this
example the liquid transport element is arranged to extend into the
reservoir in the region where it is widest in the axial direction,
i.e. into the "lobes" of the oval reservoir around the air channel.
The portions of the liquid transport element that extend into the
reservoir may, for example, have a length, as measured from the
interior of the air channel wall, in the range 2 mm to 8 mm, e.g.
in the range 3 mm to 7 mm or in the range 4 mm to 6 mm. The
specific geometry in this regard (and for other aspects of the
configuration) may be chosen having regard to a desired rate of
liquid transport, for example having regard to the capillary
strength of the liquid transport element and the viscosity of the
liquid, and may be established for a given cartridge design through
modelling or empirical testing.
[0103] Another aspect of some particular cartridge configurations
in accordance with certain embodiments of the disclosure is the
manner in which the air channel is routed through the cartridge,
and in particular from the air inlet to the vicinity of the heating
element (the aerosol generation region). In particular, whereas in
a conventional cartridges an air inlet is typically provided at the
interface end of the cartridge, in accordance with certain
embodiments of the disclosure, an air inlet for the cartridge is
located in a side wall of the housing part at a position which is
further from the interface end than at least a part of the
resilient plug that seals an end of the reservoir. Thus, the air
channel in the cartridge is initially routed from the air inlet
towards the interface end and bypasses the resilient plug before
changing direction and entering the aerosol generation chamber
through the resilient plug. This can allow the outer surface of the
cartridge at the interface end, where it is closest to the heating
element, to be closed, thereby helping to reduce the risk of
leakage from the cartridge, both in terms of liquid coming through
the openings in the air channel which is not retained by the liquid
transport element in the air channel (e.g. due to
saturation/agitation) or liquid that has being vaporized but
condensed back to liquid in the air channel during use. In some
implementations, a distance from air inlet to the interface end of
the housing part may be at least 5 mm, 6 mm, 7 mm, 8 mm, 9 mm or 10
mm.
[0104] In some example implementations an absorbent element, for
example a portion of sponge material or a series of channels
forming a capillary trap, may be provided between the air inlet and
the aerosol generation chamber, for example in the region air
channel formed between the base of the resilient plug and the end
cap, to further help reduce the risk of leakage by absorbing liquid
that forms in the air channel and so helping prevent the liquid
travelling around the air channel through the air inlet or towards
the aerosol outlet.
[0105] In some example implementations the air channel from the air
inlet to the aerosol outlet may have its smallest cross-sectional
area where it passes through the hole 106 in the resilient plug.
That is to say, the hole in the resilient plug may be primarily
responsible for governing the overall resistance to draw for the
electronic cigarette.
[0106] Another aspect of some particular cartridge configurations
in accordance with certain embodiments of the disclosure is the
manner in which the dividing wall element divides the air reservoir
into two regions, namely a main region above the dividing wall
(i.e. towards a mouthpiece end of the cartridge) and a
liquid-supply region below the dividing wall (i.e. on the same side
of the dividing wall as where the liquid transport element extends
from the heating element into the reservoir). The dividing wall
includes openings to govern the flow of liquid on the main region
to the liquid supply region. The dividing wall can help retain
liquid in the liquid supply region of the reservoir, example when
the electronic cigarette is tilted through various orientations,
which can help avoid dry out. The dividing wall can also
conveniently provide a mechanical stop for the resilient plug to
abut/press against so as to help correctly locate the resilient
plug during assembly and maintain the resilient plug in slight
compression between the dividing wall and the end cap when the
cartridge is assembled.
[0107] In the example discussed above, the dividing wall is formed
as a separate element form the housing part, wherein an inner
surface of the housing part includes one or more protrusions
arranged to contact the side of the dividing wall facing the
mouthpiece end of the cartridge to locate the dividing wall along a
longitudinal axis of the cartridge, but in other examples the
dividing wall may be integrally formed with the housing part.
[0108] In the example discussed above the dividing wall is in the
form of an annular band around the air channel and comprises four
fluid communication openings 150 located in respective quadrants of
the band. However, more or fewer openings through the dividing wall
may be provided in different implementations. Individual openings
may, for example, have an area of between 4 mm.sup.2 and 15
mm.sup.2.
[0109] A combined area for the at least one openings as a fraction
of the total area of the dividing wall exposed to liquid supply
region of the reservoir region may be, for example, from 20% to
80%; 30% to 70% or 40% to 60%.
[0110] It will be appreciated that while the above description has
focused on some specific cartridge configurations comprising a
number of different features, cartridges in accordance with other
embodiments of the disclosure may not include all these features.
For example, in some implementations an air path generally of the
kind discussed above, i.e. with an air inlet which is in a sidewall
of the cartridge and closer to the mouthpiece end of the cartridge
than the heating element, may be provided in a cartridge which does
not include a resilient plug with an outer sealing wall which
extends around the heating element and/or does not include a
dividing wall element of the kind discussed above. Similarly, a
cartridge which does include a resilient plug with an outer sealing
wall which extends around the heating element may have an air inlet
into the cartridge which is at the interface end of the cartridge,
and not in a sidewall, and which may also not have a dividing wall
element of the kind discussed above. Furthermore, a cartridge which
does include a dividing wall element, might not include an air
inlet located further from the interface end of the cartridge than
the heating element and/or an extended outer sealing wall for a
resilient plug as discussed above.
[0111] Thus, there has been described a cartridge for an aerosol
provision system comprising the cartridge and a control unit,
wherein the cartridge comprises: a housing part having a mouthpiece
end and an interface end, wherein the mouthpiece end includes an
aerosol outlet for the cartridge and the interface end includes an
interface for coupling the cartridge to the control unit; an air
channel extending from an air inlet for the cartridge to the
aerosol outlet, wherein the air channel is defined by an air
channel wall; a reservoir within the housing part for liquid for
aerosolization, wherein an end of the reservoir at the interface
end of the housing part is sealed by a resilient plug comprising a
base part and an outer wall extending away from the base part
towards the mouthpiece end of the housing part, wherein the outer
wall of the resilient plug forms a seal with an inner wall of the
housing part; a heating element for heating liquid from the
reservoir to generate aerosol in an aerosol generation region of
the air channel for user inhalation; and a liquid transport element
for transporting liquid from the reservoir to the heating element
through an opening in the air channel wall, wherein the opening in
the air channel wall is located nearer to the base part of the
resilient plug than the top of the outer wall of the resilient plug
so that a portion of the liquid transport element extends into the
reservoir in a region surrounded by the outer wall of the resilient
plug.
[0112] There has also been described a cartridge for an aerosol
provision system comprising the cartridge and a control unit,
wherein the cartridge comprises: a housing part having a mouthpiece
end and an interface end connected by a side wall, wherein the
mouthpiece end includes an aerosol outlet for the cartridge and the
interface end includes an interface for coupling the cartridge to a
control unit; an air channel extending from an air inlet for the
cartridge to the aerosol outlet; a reservoir within the housing
part containing liquid for aerosolization, wherein an end of the
reservoir at the interface end of the housing part is sealed by a
resilient plug, and wherein an outer wall of the resilient plug
forms a seal with an inner surface of the housing part; a heating
element for heating liquid from the reservoir to generate aerosol
in an aerosol generation region of the air channel; and a liquid
transport element for transporting liquid from the reservoir to the
heating element; wherein the air inlet for the cartridge is located
in the side wall of the housing part at a position which is further
from the interface end than at least a part of the resilient
plug.
[0113] There has also been described a cartridge for an aerosol
provision system comprising the cartridge and a control unit,
wherein the cartridge comprises: a housing part having a mouthpiece
end and an interface end, wherein the mouthpiece end includes an
aerosol outlet for the cartridge and the interface end includes an
interface for coupling the cartridge to a control unit; an air
channel extending from an air inlet in the housing part to the
aerosol outlet; a reservoir within the housing part containing
liquid for aerosolization, wherein an end of the reservoir at the
interface end of the housing part is sealed by a resilient plug,
wherein the reservoir includes a dividing wall between a first
reservoir region on a side of the dividing wall facing the mouth
piece end of the housing part and a second reservoir region on a
side of the dividing wall facing the interface end of the housing
part, wherein the dividing wall comprises at least one fluid
communication opening to provide fluid communication between the
first reservoir region and the second reservoir region; and a
liquid transport element arranged to transport liquid from the
second region of the reservoir to a heating element for generating
aerosol in an aerosol generation region for user inhalation.
[0114] Also described are the embodiments as set out in the clauses
at the end of this specification.
[0115] While the above described embodiments have in some respects
focused on some specific example aerosol provision systems, it will
be appreciated the same principles can be applied for aerosol
provision systems using other technologies. That is to say, the
specific manner in which various aspects of the aerosol provision
system function, for example in terms of the underlying form of the
heating element or heating element technology used are not directly
relevant to the principles underlying the examples described
herein.
[0116] In order to address various issues and advance the art, this
disclosure shows by way of illustration various embodiments in
which the claimed invention(s) may be practiced. The advantages and
features of the disclosure are of a representative sample of
embodiments only, and are not exhaustive and/or exclusive. They are
presented only to assist in understanding and to teach the claimed
invention(s). It is to be understood that advantages, embodiments,
examples, functions, features, structures, and/or other aspects of
the disclosure are not to be considered limitations on the
disclosure as defined by the claims or limitations on equivalents
to the claims, and that other embodiments may be utilized and
modifications may be made without departing from the scope of the
claims. Various embodiments may suitably comprise, consist of, or
consist essentially of, various combinations of the disclosed
elements, components, features, parts, steps, means, etc. other
than those specifically described herein, and it will thus be
appreciated that features of the dependent claims may be combined
with features of the independent claims in combinations other than
those explicitly set out in the claims. The disclosure may include
other inventions not presently claimed, but which may be claimed in
future.
[0117] For instance, although the detailed description has been
described with reference to a "liquid" in the cartridge/aerosol
provision system, it will be appreciated that this liquid may be
replaced with any aerosolizable material. Equally, where an
aerosolizable material is used, it will be appreciated that in some
embodiments this aerosolizable material may comprise a liquid.
First Set of Clauses
[0118] 1. A cartridge for an aerosol provision system comprising
the cartridge and a control unit, wherein the cartridge
comprises:
[0119] a housing part having a mouthpiece end and an interface end,
wherein the mouthpiece end includes an aerosol outlet for the
cartridge and the interface end includes an interface for coupling
the cartridge to a control unit;
[0120] an air channel extending from an air inlet in the housing
part to the aerosol outlet;
[0121] a reservoir within the housing part containing liquid for
aerosolising, wherein the reservoir includes a dividing wall
element defining a dividing wall between a first reservoir region
on a side of the dividing wall facing the mouth piece end of the
housing part and a second reservoir region on a side of the
dividing wall facing the interface end of the housing part, wherein
the dividing wall comprises at least one fluid communication
opening to provide fluid communication between the first reservoir
region and the second reservoir region;
[0122] a liquid transport element arranged to transport liquid from
the second region of the reservoir to a heating element for
generating aerosol in an aerosol generation region for user
inhalation;
an aerosol outlet tube, integrally formed with the dividing wall
element, to provide a portion of the air channel between the
aerosol generation region and the aerosol outlet. 2. The cartridge
of clause 1, wherein the aerosol outlet tube extends beyond the
dividing wall in a direction towards the mouthpiece end. 3. The
cartridge of clause 1 or 2, wherein the dividing wall element is
made of a plastic material. 4. The cartridge of any of clause 1 to
3, wherein the dividing wall element is made of polypropylene. 5.
The cartridge of any of clause 1 to 4, wherein an end of the
reservoir at the interface end of the housing part is sealed by a
plug. 6. The cartridge of clause 5, wherein the aerosol outlet tube
further comprises a slot which cooperates with a slot in the plug
to form an opening in the air channel wall for the liquid transport
element. 7. The cartridge of clause 5 or 6, wherein the dividing
wall element is positioned in the cartridge to provide a stop for
the plug such that the plug abuts the dividing wall element. 8. The
cartridge of clause 5 or 6, wherein the plug comprises a base part
and an outer wall extending away from the base part towards the
mouthpiece end of the housing part, wherein a top surface of the
outer wall abuts a peripheral part of the dividing wall element. 9.
The cartridge of any of clauses 1 to 8, wherein the air channel
passes through an air channel opening in the dividing wall element.
10. The cartridge of any of clauses 5 to 9, wherein the dividing
wall element includes one or more projections extending away from
the plane of the dividing wall towards the interface end of the
cartridge which engage with one or more corresponding recesses in
the plug. 11. The cartridge of any of clauses 5 to 10, wherein the
dividing wall element includes one or more projections extending
away from the plane of the dividing wall towards the interface end
of the cartridge which engage with respective cradles formed in the
plug to define a liquid transport element opening through which the
liquid transport element passes. 12. The cartridge of any of clause
1 to 11, wherein the dividing wall element extends around the
aerosol outlet tube. 13. The cartridge of any of clauses 1 to 12,
wherein the liquid transport element comprises a capillary wick.
14. The cartridge of any of clauses 1 to 13, wherein the heating
element comprises a heater. 15. The cartridge of any of clauses 1
to 14, wherein the liquid transport element and the heating element
comprise a single integrated element. 16. An aerosol provision
system comprising the cartridge of any one of clauses 1 to 15 and a
control unit, wherein the control unit comprises a cartridge
receiving section that includes an interface arranged to
cooperatively engage with the interface at the interface end of the
cartridge so as to releasably couple the cartridge to the control
unit, wherein the control unit further comprises a power supply and
control circuitry configured to selective supply power from the
power supply to the heating element in the cartridge via their
cooperatively engaging interfaces.
Second Set of Clauses
[0123] 1. A cartridge for an aerosol provision system, wherein the
cartridge comprises: a heating element for heating liquid from a
reservoir to generate aerosol in the aerosol generation region; an
air channel extending through the cartridge for delivering air to
the heating element; and at least two contact electrodes mounted to
the cartridge to allow power to be supplied to the heating element;
wherein each contact electrode comprises a portion defining a
knurled outer surface which is embedded in a portion of the
cartridge for securing the contact electrode to the cartridge. 2. A
cartridge according to clause 1, wherein the cartridge further
comprises:
[0124] a housing part having a mouthpiece end and an interface end,
wherein the mouthpiece end includes the aerosol outlet for the
cartridge and the interface end includes an interface for coupling
the cartridge to a control unit;
[0125] wherein an end of the reservoir at the interface end of the
housing part is sealed by a plug comprising a base part and an
outer wall extending away from the base part towards the mouthpiece
end of the housing part, wherein the outer wall of the plug forms a
seal with an inner surface of the housing part;
wherein the portion of the cartridge is the plug. 3. A cartridge
according to clause 2, wherein the plug is injection moulded around
each contact electrode. 4. A cartridge according to any of clause 1
to 3, wherein at least one contact electrode further comprises a
flange portion which projects outwardly around the contact
electrode, wherein the flange portion rests on a surface from the
cartridge. 5. A cartridge according to clause 4, wherein at least
one contact electrode comprises no more than one flange portion
which projects outwardly around the contact electrode, wherein the
flange portion rests on a surface from the cartridge. 6. A
cartridge according to clause 4 or 5, when further dependent on
clause 2 or clause 3, wherein the surface from the cartridge is a
surface from an end cap from the cartridge which is located at the
interface end, or a surface from the plug. 7. A cartridge according
to any of clause 4 to 6, wherein each flange portion has a
thickness of no more than 1 mm. 8. A cartridge according to any of
clause 1 to 7, wherein each contact electrode is gold plated. 9. A
cartridge according to any of clause 1 to 8, wherein a portion of
the air channel extends between the contact electrodes. 10. A
cartridge according to any of clause 1 to 9, wherein the cartridge
comprises no more than two contact electrodes. 11. An aerosol
provision system comprising the cartridge of any one of clauses 1
to 10 and a control unit, wherein the control unit comprises a
cartridge receiving section that includes an interface arranged to
cooperatively engage with an interface from the cartridge so as to
releasably couple the cartridge to the control unit, wherein the
control unit further comprises a power supply and control circuitry
configured to selective supply power from the power supply to the
heating element in the cartridge via their cooperatively engaging
interfaces.
Third Set of Clauses
[0126] 1. A control unit for an aerosol provision system comprising
a cartridge and the control unit, wherein the control unit
comprises:
[0127] an outer housing including a receptacle wall that defines a
receptacle having an open first end and a second end, wherein the
receptacle wall comprises at least one opening;
[0128] a body configured to be inserted inside the receptacle via
the open first end towards the second end, the body comprising a
protrusion, wherein the protrusion is configured to extend through
the opening when the body is fully inserted inside the
receptacle;
[0129] wherein the control unit comprises at least one deformable
portion which is configured to deform as the body is inserted into
the receptacle to allow the body to be fully inserted into the
receptacle, and to allow the protrusion to extend through the
opening of the receptacle wall.
2. A control unit according to clause 1, wherein the deformable
portion is configured to elastically deform as the body is inserted
into the receptacle. 3. A control unit according to any of clause 1
or 2, wherein the body comprises the deformable portion. 4. A
control unit according to clause 3, wherein the body comprises a
slot defining a cantilevered portion for the body, wherein the
cantilevered portion is the deformable portion. 5. A control unit
according to clause 4, wherein the protrusion is located on the
cantilevered portion. 6. A control unit according to any of clause
1 to 5, wherein the protrusion is a button for controlling an
operation of the control unit. 7. A control unit according to any
of clause 1 to 6, wherein the body comprises a battery and control
circuitry for controlling the operation of the aerosol provision
system. 8. A control unit according to any of clause 1 to 7,
wherein the body comprises at least two contact electrodes, wherein
each contact electrode extends through a respective opening in the
body. 9. A control unit according to any of clause 1 to 8, wherein
the outer housing is made of plastic. 10. A control unit according
to any of clause 1 to 9, wherein the body comprises an integral
seal, wherein the seal is located at an end of the body more
proximal the open first end than the second end of the receptacle
when the body is fully inserted inside the receptacle. 11. A
provision system comprising a cartridge and the control unit of any
of clause 1 to 10, wherein the cartridge comprises a heating
element for heating liquid from a reservoir to generate aerosol in
an aerosol generation region; wherein the control unit comprises a
cartridge receiving section that includes an interface arranged to
cooperatively engage with the cartridge so as to releasably couple
the cartridge to the control unit into a position where the
cartridge is at least partially within the receptacle.
Fourth Set of Clauses
[0130] 1. A cartridge for an aerosol provision system, wherein the
cartridge comprises: a heating element for heating liquid from a
reservoir to generate aerosol in the aerosol generation region; an
air channel extending through the cartridge for delivering air to
the heating element; and at least two contact electrodes mounted to
the cartridge to allow power to be supplied to the heating element,
wherein each contact electrode comprises a heating element lead for
transferring power between the contact electrode and the heating
element; wherein a portion of each heating element lead is located
inside a recess located in a portion of the contact electrode
associated with the heating element lead; wherein the portion of
the contact electrode is crimped around the portion of the heating
element lead to secure the portion of the contact electrode inside
the recess. 2. A cartridge according to clause 1, wherein each
contact electrode is gold plated. 3. A cartridge according to
clause 1 or 2, wherein the crimped portion of each contact
electrode comprises a circular cross section. 4. A cartridge
according to clause 1 or 2, wherein the crimped portion of each
contact electrode comprises a plus-shaped cross section. 5. A
cartridge according to any of clause 1 to 4, wherein within each
recess, at least 50% of the outside surface area of each heating
element lead is in contact with the portion of the contact
electrode. 6. A cartridge according to any of clause 1 to 5,
wherein the maximum width of each contact electrode is less than 10
mm. 7. A method of crimping a first component around a second
component between a pair of crimping members, wherein the pair of
crimping members comprises: a first crimping member comprising a
first contact face which extends across the width and the height of
the first crimping member, wherein a first recess extending across
the height of the first crimping member and extending across a
portion of the width of the first crimping member is located in the
first contact face; a second crimping member comprising a second
contact face which extends across the width and the height of the
second crimping member, wherein a second recess extending across
the height of the second crimping member and extending across a
portion of the width of the second crimping member is located in
the second contact face; wherein the method comprises the steps of:
placing the first and second components between the first and
second contact faces, wherein the first component is located around
the second component; moving the contact faces together in a depth
direction perpendicular to the width and height of the first and
second crimping members such that the second component is deformed
between the two contact faces, and such that the second component
is crimped around the first component to secure the first and
second components together. 8. A method according to clause 7,
wherein the first recess is a first semi cylindrical recess, and
the second recess is a second semi cylindrical recess. 9. A method
according to clause 7, wherein the first recess is a first T-shaped
recess, and the second recess is a second T-shaped recess. 10. A
method of forming material according to clause 9, wherein the edges
from the first T-shaped recess which extend across the height of
the first crimping member are chamfered. 11. A method of forming
material according to clause 9 or 10, wherein the edges from the
second T-shaped recess which extend across the height of the second
crimping member are chamfered. 12. A method of forming material
according to any of clause 9 to 11, wherein each T-shaped recess is
defined by an elongate shoulder portion which extends in the width
direction of the crimping member in which the T-shaped recess is
located, and an elongate leg portion which extends perpendicular to
the shoulder portion in the depth direction of the crimping member.
13. A method according to any of clause 7 to 12, wherein each
recess comprises a protrusion extending towards the contact face of
the crimping member in which the recess is located, wherein the
protrusion does not extend across the complete height of the
recess. 14. A method of forming material according to clause 13,
wherein the protrusion is located midway along the height of the
recess in which the protrusion is located. 15. A method of forming
material according to clause 13 or 14, wherein the maximum height
of the protrusion is no more than 5 mm. 16. A method of forming
material according to any of clause 13 to 15, when further
dependent on clause 12, wherein the protrusion is located at an end
of the elongate leg portion. 17. A method of forming material
according to any of clause 7 to 16, wherein the maximum height of
each recess is less than 30 mm. 18. A method of forming material
according to any of clause 7 to 17, wherein the maximum depth of
each recess is no more than 25 mm. 19. A method of forming material
according to any of clause 7 to 18, wherein the maximum width of
each recess is no more than 50 mm. 20. A method of forming material
according to any of clause 7 to 19, wherein the first component is
gold plated. 21. A method of forming material according to any of
clause 7 to 20, wherein the first component is a heating element
lead for transferring power between a contact electrode and the
heating element, and wherein the second component is the contact
electrode. 22. A cartridge according to any one of clauses 1-6,
wherein each contact electrode and heating element lead are crimped
together using the method according to clause 21.
* * * * *